Hitachi ZW180 ZW220 ZW250 ZW310 Wheel Loader Workshop Repair Service Manual + Operator's Manual PDF - MHITZW220ZW310OPES.zip

The complete service and repair guide for Hitachi ZW220, ZW250, and ZW310 Wheel Loaders comes with Electrical Wiring Diagrams and every piece of shop-level detail needed to service, troubleshoot, and rebuild these machines.

Inside the Hitachi ZW220, ZW250, and ZW310 Wheel Loaders workshop manual, you'll find:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 3,033 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Language: English

TT4GB-E-00 - Hitachi ZW220, ZW250 Wheel Loader Technical Manual (Troubleshooting).pdf

TT4HA-E-00 - Hitachi ZW310 Wheel Loader Technical Manual (Troubleshooting).pdf

W4GC-E-00 - Hitachi ZW220, ZW250 Wheel Loader (Standard Specification) Workshop Manual.pdf

W4HA-E-00 - Hitachi ZW310 Wheel Loader Workshop Manual.pdf

WCLA-0595-ZW - Hitachi ZW220, ZW250, ZW310 Transmission Control (TCM Transmission).pdf

WCLA-0596-ZW - Hitachi ZW310 Hydraulic Circuit Diagram (EU Standard).pdf

EM4GF-EN2-1 - Hitachi ZW180, ZW220, ZW250, ZW310 Wheel Loader Operator's Manual.pdf

TO4HA-E-00 - Hitachi ZW310 Wheel Loader Technical Manual (Operational Principle).pdf

EM4GFEN21 - Hitachi ZW180, ZW220, ZW250, ZW310 Wheel Loader Operator' Manual...2

TO4HAE00 - Hitachi ZW310 Wheel Loader Technical Manual (Operational Principle)...336

Operational Principle...336

INTRODUCTION...338

SECTION AND GROUP...340

SECTION 1...342

Group 1 Specifications...344

Specifications...344

Group 2 Component Layout...346

Main Component Layout...346

Electrical Component Layout...349

Electrical System (Cab)...350

Electrical System...351

Electrical System (Right Console)...352

Electrical System (Monitor and Switchs)...353

Monitor Panel...354

Engine and Fan Pump...355

Pump Device and Drive Unit...356

Control Valve...357

Ride Control Valve,Charging Block ...358

Steering Valve and Emergency Steering ...359

Group 3 Component Specifications...360

Engine...360

Engine Accessories...364

Hydraulic Component...365

Electrical Component...369

SECTION 2...374

Group 1 Control System...376

Outline...376

Engine Control...381

Pump Control...390

Transmission Control...395

Other Controls...416

Control by Electric and Hydraulic ...426

Group 2 ECM System...440

Outline...440

Fuel Injection Control...441

Group 3 Hydraulic System...446

Outline...446

Main Circuit...447

Pilot Circuit...458

Steering Circuit...471

Hydraulic Drive Fan Circuit...477

Group 4 Electrical System...480

Outline...480

Main Circuit...481

Electric Power Circuit...482

Indicator Light Check Circuit...483

Accessory Circuit...484

Preheat Circuit...485

Starting Circuit...487

Charging Circuit...491

Serge Voltage Prevention Circuit...493

Engine Stop Circuit...495

Lamplight Circait...496

Head Light Circuit...497

Turn Signal Circuit...501

Brake Light Circuit...502

Hazard Light Circuit...503

Horn Circuit...504

Reverse Light/Buzzer Circuit...505

Parking Brake Circuit...507

Emergency Steering Check ...509

SECTION 3...514

Group 1 Pump Device...516

Outline...516

Main Pump...517

Regulator...519

Priority Valve...533

Pilot Pump,Pump Delivery ...534

Steering Main Relief Valve...535

Group 2 Control Valve...536

Outline...536

Hydraulic Circuit...543

Main Relief Valve...547

Overload Relief Valve...549

Restriction Valve...552

Negative Control Valve...553

Flow Rate Control Valve...555

Group 3 Hydraulic Fan Motor...558

Outline...558

Operation...561

Flow Control Valve...563

Reverse Control Valve...565

Fun Pump...567

Group 4 Pilot Valve...568

Outline...568

Construction...569

Operation...570

Group 5 Steering Valve...574

Outline...574

Operation...577

Steering Overload Relief Valve...581

Group 6 Pilot Valve...584

Outline (Two Lever Type Pilot Valve for ...584

Operation...585

Electromagnetic Detent...589

Outline (Joystick Type Pilot Valve for ...590

Operation...591

Electromagnetic Detent...595

Outline (Lever Type Pilot Valve for ...596

Operation...597

Outline (Joystick Type Pilot Valve for ...600

Operation...601

Group 7 Charging Block...608

Outline...608

Priority Valve...613

Pilot Relief Valve...614

Pump Torque Control Proportional ...615

Service Brake Accumulator, ...616

Parking Brake Solenoid Valve...617

Service Brake Pressure Sensor...619

Parking Brake Pressure Sensor...619

Group 8 Ride Control Valve...620

Outline...620

Operation...623

Charge Cut Spool...625

Over Load Relief Valve...627

Ride Control Accumlator...629

Drain Plug...630

Group 9 Drive Unit...632

Outline...632

Torque Converter...633

Transmission...635

Transmisson Regulator Valve...657

Transmission Control Valve...659

Manual Spool (Emergency Travel ...667

Proportional Solenoid Valve...669

Group 10 Axle...670

Outline...670

Differential...671

Torque Proportioning Differential (TPD)...675

Limited Slip Differential (LSD)...677

Service Brake...679

Final Drivel Axle Shaft...681

Group 11 Brake Valve...682

Outline...682

Operation...685

Group 12 Others...688

Pilot Shutoff Valve...688

Propeller Shaft...689

Emergency Steering Check Block...690

Emergency Steering Pump (Optional)...691

TT4GBE00 - Hitachi ZW220, ZW250 Wheel Loader Technical Manual (Troubleshooting)...696

ZW220/250_TT4GB-E-00...696

INTRODUCTION...697

SAFETY...699

RECOGNIZE SAFETY INFORMATION...699

UNDERSTAND SIGNAL WORDS...699

FOLLOW SAFETY INSTRUCTIONS...700

PREPARE FOR EMERGENCIES...700

WEAR PROTECTIVE CLOTHING...701

PROTECT AGAINST NOISE...701

NSPECT MACHINE...701

GENERAL PRECAUTIONS FOR CAB...702

USE HANDHOLDS AND STEPS...703

ADJUST THE OPERATOR' SEAT...703

ENSURE SAFETY BEFORE RISING FROMOR LEAVING OPERATOR’S SEAT...703

FASTEN YOUR SEAT BELT...704

MOVE AND OPERATE MACHINE SAFELY...704

HANDLE STARTING AIDS SAFELY...704

OPERATE ONLY FROM OPERATOR'SEAT...705

JUMP STARTING...705

INVESTIGATE JOB SITE BEFOREHAND...706

EQUIPMENT OF HEAD GUARD, ROPS,FOPS...707

PROVIDE SIGNALS FOR JOBS INVOLVINGMULTIPLE NUMBERS OF MACHINES...707

KEEP RIDERS OFF MACHINE...708

DRIVE SAFELY...708

DRIVE MACHINE SAFELY (WORK SITE)...708

DRIVE SAFELY WITH BUCKET LOADED...709

DRIVE ON SNOW SAFELY...709

TRAVEL ON PUBLIC ROADS SAFELY...709

AVOID INJURY FROM ROLLAWAY ACCIDENTS...710

AVOID ACCIDENTS FROM BACKING UPAND TURNING...711

AVOID POSITIONING BUCKET OVERANYONE...712

AVOID TIPPING...712

NEVER UNDERCUT A HIGH BANK...713

DIG WITH CAUTION...713

PERFORM TRUCK LOADING SAFELY...713

AVOID POWER LINES...714

PRECAUTIONS FOR OPERATION...714

PRECAUTIONS FOR LIGHTENING...714

OBJECT HANDLING...714

PROTECT AGAINST FLYING DEBRIS...715

PARK MACHINE SAFELY...715

STORE ATTACHMENTS SAFELY...716

TRANSPORT SAFELY...716

HANDLE FLUIDS SAFELY-AVOID FIRES...717

PRACTICE SAFE MAINTENANCE...718

WARN OTHERS OF SERVICE WORK...719

SUPPORT MACHINE PROPERLY...719

STAY CLEAR OF MOVING PARTS...719

SUPPORT MAINTENANCE PROPERLY...720

PREVENT PARTS FROM FLYING...720

PREVENT BURNS...721

REPLACE RUBBER HOSES PERIODICALLY...721

PREVENT FIRES...723

EVACUATING IN CASE OF FIRE...724

BEWARE OF EXHAUST FUMES...724

PRECAUTIONS FOR WELDING ANDGRINDING...724

AVOID HEATING NEAR PRESSURIZEDFLUID LINES...725

AVOID APPLYING HEAT TO LINES CONTAININGFLAMMABLE FLUIDS...725

REMOVE PAINT BEFORE WELDING ORHEATING...725

BEWARE OF ASBESTOS DUST...726

PREVENT BATTERY EXPLOSIONS...726

SERVICE AIR CONDITIONING SYSTEMSAFELY...726

HANDLE CHEMICAL PRODUCTS SAFELY...727

DISPOSE OF WASTE PROPERLY...727

BEFORE RETURNING THE MACHINE TOTHE CUSTOMER...728

SECTION AND GROUPCONTENTS...729

SECTION 4 OPERATIONALPERFORMANCE TEST...731

Group 1 Introduction...733

Operational Performance Tests...733

Preparation for Performance Tests...734

Group 2 Standard...735

Operational PerformanceStandard Table ...735

Main Pump P-Q Curve...745

Sensor Activating Range...747

Group 3 Engine Test...749

Engine Speed...749

Engine Compression Pressure...751

Valve Clearance Adjustment...752

Lubricant Consumption...755

Group 4 Wheel Loader Test...757

Travel Speed...757

Service Brake Function Check...758

Service Brake Wear Amount...759

Parking Brake Function Check...760

Bucket and Bell Crank StopperClearances ...762

Hydraulic Cylinder Cycle Time...764

Cylinder Drift Check...766

Bucket Levelness...767

Control Lever Operating Force...768

Control Lever Stroke...769

Group 5 Component Test...771

Primary Pilot Pressure...771

Secondary Pilot Pressure...773

Solenoid Valve Set Pressure...774

Main Pump Delivery Pressure...776

Main Relief Valve Set Pressure...778

Steering Relief Pressure...782

Overload Relief Valve Set Pressure...784

Main Pump Flow Rate...786

Regulator Adjustment...790

Service Brake Pressure (Front and Rear)...792

Parking Brake Pressure...794

Brake Accumulated Pressure...796

Brake Warning Set Pressure (Decrease)...798

Brake Warning Set Pressure (Increase)...800

Transmission Clutch Pressure...802

Torque Converter Pressure(Inlet and Outlet)...804

Group 6 Adjustment...807

Transmission Learning...807

Lift Arm Angle SensorLearning (Optional)...812

Drive Belt Tension Adjustment...814

SECTION 5 TROUBLESHOOTING...817

Group 1 Diagnosing Procedure...821

Introduction...821

Diagnosing Procedure...822

How to Operate Service Made ofMonitor ...826

Display List of Monitor Service Mode...827

Group 2 Dr.ZX...829

Outline...829

Operation...830

Self-Diagnosing Result...832

Select Controller...834

Main Controller...835

Main Menu Monitor Display (MainController) ...836

Setting (Main Controller)...840

Record Data Display (Main Controller)...847

Password Change (Main Controller)...848

Engine Controller...849

Monitor Display (Engine Controller)...850

Recorded Data Display (EngineController) ...854

Password Change (Engine Controller)ICF Controller ...855

ICF Various Setup (ICF Controller)...857

Save Data Check (ICF Controller)...868

Password Change (ICF Controller)...869